E1294W-WWEN NVent ERICO Cadweld Installation and Inspection Guide - Nvent

The ERICO CADWELD Process
nVent ERICO Cadweld

Installation and
Inspection Guide
WARNING
1. nVent ERICO products shall be installed and used only as indicated in nVent ERICO product
instruction sheets and training materials. Instruction sheets are available at nVent.com/ERICO and
from your nVent ERICO customer service representative.
2. nVent ERICO products must never be used for a purpose other than the purpose for which they were
designed or in a manner that exceeds specified load ratings.
3. All instructions must be completely followed to ensure proper and safe installation and performance.
4. Improper installation, misuse, misapplication or other failure to completely follow nVent ERICO’s
instructions and warnings may cause product malfunction, property damage, serious bodily injury
and death.
GENERAL AND SAFETY INSTRUCTIONS:
A. Only nVent ERICO manufactured equipment and materials should be used to make nVent ERICO
Cadweld connections.
B. Do not connect items except as detailed in instruction sheets. Failure to comply with these
instructions may result in improper and unsafe connections, damage to items being connected,
bodily injury and
property damage.
C. Do not use worn or broken equipment which could cause leakage.
D. Do not alter equipment or material without nVent ERICO authorization.
E. When using Cadweld do not use welding material package if damaged or not fully intact. When using
Cadweld Plus, do not tamper with or disassemble the welding material unit.
F. Make connections in conformance with Cadweld instructions and all governing codes.
1. Personnel should be properly trained in the use of this product and must wear safety glasses
and gloves.
2. Avoid contact with hot materials.
3. Advise nearby personnel of welding operations in the area.
4. Remove or protect fire hazards in the immediate area.
5. Provide adequate ventilation to the work area.
6. Do not smoke when handling starting material.
7. Avoid direct eye contact with “flash” of light from ignition of starting material.
G. Welding material is an exothermic mixture and reacts to produce hot molten material with
temperatures in excess of 1400°C (2500°F) and a localized release of smoke. These materials are not
explosive. Ignition temperatures are in excess of 900°C (1650°F) for welding material.
H. Adhering to the Cadweld welding procedures will minimize risk of burns and fire caused by hot molten
material spillage. In case of fire, use of water or CO 2 will aid in control of burning containers. Large
quantities of water will aid in controlling a fire should the exothermic materials become involved.
Water should be applied from a distance.
1. Make sure there is proper mold fit and assembly of equipment.
2. Avoid moisture and contaminants in mold and materials being welded. Contact between hot molten
metal and moisture or contaminants may result in spewing of hot material.
3. Base material thickness must be sufficient for the size and type of connection being made to prevent
melt-through and leakage of hot molten metal.
I. Applications or conditions may exist which require special considerations. The following are
examples, but are not intended to be a complete listing of applications/conditions.
CONNECTIONS TO PIPE/VESSELS
For use with cast iron pipe or heavy casting meeting ASTM A47-84, A48-83, A126-84, A278-85, or
A377-89. DO NOT USE ON CAST IRON SOIL PIPE (ASTM A74-93). Evaluate possible effects of Cadweld
connections to structural members and thin-wall materials; vessels/piping systems that are pressurized,
closed or containing (or having contained) flammable/explosive/hazardous materials. Evaluation
should be made prior to use, based on conditions of use and applicable codes, and should incorporate
as a minimum, effects of melt-through of hot material; structural/metallurgical effects of Cadweld
connections, pressure (temperature) build-up and fire/chemical decomposition hazards.
CONNECTIONS TO REBAR
Application of the Cadweld connection may have an effect on the rebar’s structural integrity. The rebar’s
chemistry and the location of the weld should be considered before making any welds to the rebar.
For lapped rebar splices, it is recommended that the connections be made near the bar end at an area
of minimum stress. If Cadweld Rebar Splices are used, the grounding connection can be made to the
splice sleeve with minimal effect on the structural characteristics of the splice.
SAFETY INSTRUCTIONS:
All governing codes and regulations and those required by the job site must be observed. Always
use appropriate safety equipment such as eye protection, hard hat, and gloves as appropriate to the
application.
WARRANTY
Cadweld products are warranted to be free from defects in material and workmanship at the time of
shipment. NO OTHER WARRANTY, WHETHER EXPRESS OR IMPLIED (INCLUDING ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), SHALL EXIST IN CONNECTION
WITH THE SALE OR USE OF ANY nVent ERICO PRODUCTS. Claims for errors, shortages, defects or
nonconformities ascertainable upon inspection must be made in writing within 5 days after Buyer’s
receipt of products. All other claims must be made in writing to nVent ERICO within 6 months from the
date of shipment or transport. Products claimed to be nonconforming or defective must, upon nVent
ERICO’s prior written approval in accordance with its standard terms and procedures governing returns,
promptly be returned to nVent ERICO for inspection. Claims not made as provided above and within the
applicable time period will be barred. nVent ERICO shall in no event be responsible if the products have
not been stored or used in accordance with its specifications and recommended procedures. nVent
ERICO will, at its option, either repair or replace nonconforming or defective products for which it is
responsible or return the purchase price to the Buyer. THE FOREGOING STATES BUYER’S EXCLUSIVE
REMEDY FOR ANY BREACH OF NVENT ERICO WARRANTY AND FOR ANY CLAIM, WHETHER
SOUNDING IN CONTRACT, TORT OR NEGLIGENCE, FOR LOSS OR INJURY CAUSED BY THE SALE OR
USE OF ANY PRODUCT.
LIMITATION OF LIABILITY
nVent ERICO excludes all liability except such liability that is directly attributable to the willful or gross
negligence of nVent ERICO’s employees. Should nVent ERICO be held liable its liability shall in no
event exceed the total purchase price under the contract. NVENT ERICO SHALL IN NO EVENT BE
RESPONSIBLE FOR ANY LOSS OF BUSINESS OR PROFITS, DOWNTIME OR DELAY, LABOR, REPAIR OR
MATERIAL COSTS OR ANY SIMILAR OR DISSIMILAR CONSEQUENTIAL LOSS OR DAMAGE INCURRED
BY BUYER.
The nVent ERICO Cadweld Process
The nVent ERICO Cadweld process is a method of making
electrical connections of copper-to-copper or copper-to-steel in
which no outside source of heat or power is required.
In this process, conductors are prepared, placed in a purpose-
designed graphite mold, and exothermically welded to produce a
permanent electrical connection.
The steps outlined below are a general demonstration of a typical
welded connection.These basic steps are used for all Cadweld
electrical connections. Be sure to read and follow the instructions
included with every mold before making a connection.
The Cadweld exothermic process is a system. Materials from
other manufacturers should not be mixed or matched with
Cadweld molds or welding material.
The Cadweld Plus Process............................................11
The Cadweld Exolon Process.......................................19
The Cadweld One Shot Process.................................. 28
The Cadweld Plus One Shot Process......................... 33
Cadweld Quality Standards.......................................... 38
nVent.com/ERICO | 1
The Cadweld Process
Fig. 1
Always wear protective safety glasses and gloves
while working with Cadweld
exothermic welding products.
Fig. 2
Gather the proper materials and equipment for the type of
connection you are making. The typical Cadweld system requires
a graphite mold, handle clamp, welding material, natural bristle
brush for mold cleaning, wire brush for cleaning/preparing
conductors, flint igniter, and propane torch.
NOTE: Additional materials may be required for your specific
application. Refer to your mold instructions. Advise nearby
personnel of welding operations in the area prior to ignition.
Fig. 3
Check to ensure the graphite mold is not worn or broken, which
could cause leakage of molten weld metal during the reaction.
2 | nVent.com/ERICO
The Cadweld Process
Fig. 4
Inspect the mold ID tag to ensure that it corresponds to the
application, indicated by the:
1. mold part number
2. conductor size
3. welding material required
4. other materials required
The mold must be correct for the conductor size and application.
DO NOT MODIFY MOLDS.
Fig. 5
Remove the small wire bracket which is used to temporarily hold
the mold together before using. Set the bracket aside.
Fig. 6
Slide the handle clamp into the pre-drilled holes with the proper
orientation for the thumbscrews.
nVent.com/ERICO | 3
The Cadweld Process
Fig. 7
Tighten the clamp thumbscrews onto the mold.
Fig. 8
Close the grips to tightly lock the mold. Check for an appropriate
seal on the mold.
Fig. 9
If the mold does not seal properly, make adjustments to tighten/
loosen the handle clamp.
4 | nVent.com/ERICO
The Cadweld Process
Fig. 10
Graphite absorbs moisture. Ignite the propane torch and dry out
the inside of the mold thoroughly on both sides, heating the mold
to approximately 250 degrees Fahrenheit (120 degrees Celsius).
Fig. 11
The conductors should be clean and dry before the connection
is made. Use a propane torch to dry wire conductors and remove
remaining cleaning residue, solvent, or water before making the
Cadweld connection.
Fig. 12
Next, use a wire brush to further prepare the surface of the
conductors (nVent ERICO T-313 or T-314 brush). Scrape the outer
surface to remove dirt and oxidation. You will notice a slight color
change.
nVent.com/ERICO | 5
The Cadweld Process
Fig. 13
Insert the conductors and position them for the connection.
Fig. 14
Close the clamp tightly once the conductors are properly
positioned.
Fig. 15
Steel disk found inside the packaging box of welding material.
6 | nVent.com/ERICO
The Cadweld Process
Fig. 16
Insert the steel disk (concave side up) into the mold. Hold the
steel disk on the side of the mold and let it slide into place.
Fig. 17
Ensure that the steel disk is properly seated.
Fig. 18
Next, take a tube of properly sized welding material
(as identified on the mold ID tag) out of the box.
nVent.com/ERICO | 7
The Cadweld Process
Fig. 19
Remove the lid over the mold crucible.
Fig. 20
Quickly pour the loose welding material powder into the mold.
Fig. 21
The bottom of the tube contains compressed material
(starting material). Tap the bottom of the tube a couple of times
to loosen this material.
8 | nVent.com/ERICO
The Cadweld Process
Fig. 22
Pour 1/4 to 1/3 of the starting material over the welding material
in the mold crucible.
Fig. 23
Close the lid and pour the remaining 3/4 to 2/3 of the starting
material into the slot on the mold cover.
NOTE: Welding material is an exothermic mixture and reacts
to produce hot molten material with temperatures in excess
of 2500 degrees Fahrenheit (1400 degrees Celsius) and a
localized release of smoke. Avoid looking directly at the “flash”
of light from ignition of starting material. Avoid inhalation of
smoke/fumes.
Fig. 24
Aiming the flint igniter from the side, ignite the starting material
on the mold cover. Withdraw the igniter quickly to prevent fouling.
Allow approximately 30 seconds for completion of the reaction
and solidification of the molten material.
nVent.com/ERICO | 9
The Cadweld Process
Fig. 25
Open the mold and remove the connection. Use care to prevent
chipping the mold. Avoid contact with hot materials. See the
“Cadweld Quality Standards” section to see whether a quality
connection has been made.
Fig. 26
Completed Cadweld connection.
Fig. 27
Cadweld graphite molds will last approximately 50 connections.
Use a soft cotton cloth or a soft bristle brush (nVent ERICO part
#T394) to clean inside the mold cavity and cover.
Fig. 28
Ready to make another Cadweld connection.
10 | nVent.com/ERICO
The Cadweld Plus Process
Fig. 1
Always wear protective safety glasses and gloves
while working with Cadweld Plus exothermic products.
Fig. 2
Prepare the proper materials and equipment for the type of
connection you are making. The Cadweld Plus system requires a
graphite mold, mold clamp, Cadweld Plus welding material cup,
natural bristle brush for mold cleaning, wire brush for cleaning/
preparing conductors, control unit, and propane torch.
Fig. 3
nVent.com/ERICO | 11
Fig. 4
Inspect the mold ID tag to ensure that it corresponds to the
application, indicated by the:
1. mold part number
2. conductor size
Fig. 5
Fig. 6
Fig. 7
Fig. 8
seal on the mold.
Fig. 9
If the mold does not seal properly, ake adjustments to tighten/
loosen the handle clamp.
Fig. 10
Fig. 11
Cadweld connection.
Fig. 12
conductors (nVent ERICO T-313 or T-314 brush). Scrape the outer
surface to remove dirt and oxidation. You will notice a slight color
change.
Fig. 13
Fig. 14
positioned.
Fig. 15
Remove the proper Cadweld Plus welding material cup from the
plastic container. Inspect the cup to ensure it is tightly sealed and
the ignition strip is securely attached to the seal.
Fig. 16
Place the cup into the top of the mold. Make sure the ignition strip
nests into the recess on the top edge when the cover is closed.
Fig. 17
Battery powered control unit.
Fig. 18
Place the ignition strip into the control unit connector. Remove or
protect fire hazards in close proximity to the connection.
Fig. 19
Close the graphite mold lid. Advise nearby personnel of welding
operations in the area.
Fig. 20
Using the control unit, press the button and hold, while you
observe the “ready” indicator light. A green light will blink for a few
seconds and then will change to a constant light. At this time, the
unit will send a charge to the ignition strip. The ignition strip will
spark inside the metal cup, initiating the Cadweld Plus exothermic
reaction.
Fig. 21
Remove the control unit connector from the ignition strip.
Open the lid and remove the used Cadweld Plus cup
from the mold.
Fig. 22
Fig. 23
Fig. 24
Cadweld graphite molds will last approximately 50 connections.
Use a soft cotton cloth or a soft bristle brush (nVent ERICO part
#T394) to clean inside the mold cavity and cover.
Fig. 25
The Cadweld Exolon Process
Fig. 1
Always wear protective safety glasses and gloves while working
with Cadweld exothermic products.
Fig. 2
connection you are making. The Cadweld Exolon system requires
a Cadweld Exolon graphite mold, handle clamp, welding material,
wire brush for cleaning/preparing conductors, battery pack, and
propane torch.
Fig. 3
Fig. 4
Inspect the mold ID tag to ensure that it corresponds
to the application, indicated by the:
1. mold part number
2. conductor size
Fig. 5
Fig. 6
Fig. 7
Fig. 8
seal on the mold.
Fig. 9
If the mold does not seal properly, make adjustments to the
handle clamp.
Fig. 10
The Exolon Process
Fig. 11
Cadweld connection.
Fig. 12
conductors and ground rod (nVent ERICO T-313 or T-314 brush).
Scrape the outer surface to remove dirt and oxidation.
You will notice a slight color change.
Fig. 13
Weld metal package (includes welding material, discs, filters and
ignitors for 4 connections).
The Exolon Process
Fig. 14
Each Exolon package contains 2 filters for a low emission
connection. Insert the white ceramic and black graphite
filters into the mold cover. (Filters must be changed every
4 connections.)
NOTE: If using XL200 welding material or higher, 3 filters
(1 white, 2 black) are included in the weld metal package.
Insert the white filter between the black filters.
Fig. 15
Fig. 16
positioned.
Fig. 17
Steel disk found inside the packaging box of welding material.
Fig. 18
Insert the steel disk (concave side up) into the mold. Hold the
steel disk on the side of the mold and let it slide into place.
Fig. 19
Ensure that the steel disk is properly seated.
Fig. 20
Next, take the tube of welding material included in the
Cadweld Exolon package and remove the lid over
the mold crucible.
Fig. 21
Quickly pour the loose welding material powder into the
Cadweld Exolon mold.
NOTE: Welding material is an exothermic mixture and reacts
to produce hot molten material with temperatures in excess
of 2500 degrees Fahrenheit (1400 degrees Celsius) and a
localized release of smoke. Avoid direct eye contact with “flash”
of light from ignition of starting material. Avoid inhalation of
smoke/fumes.
Fig. 22
Place the graphite Cadweld Exolon cover onto the mold, with the
larger side facing down.
Fig. 23
Next, take an igniter pin and place it halfway into the small hole
on the side of the mold, with the loop side facing into the hole.
Spread the wire leads.
Fig. 24
Cadweld Exolon battery pack.
Fig. 25
Take the alligator clips and clip them onto the wire leads. Remove
or protect fire hazards in close proximity to the connection.
Advise nearby personnel of welding operations in the area.
Fig. 26
Using the Cadweld Exolon battery pack, press the button. At this
time, the unit will send a charge to the igniter pin. The igniter pin
will initiate the Cadweld Exolon exothermic reaction.
Fig. 27
Remove the alligator clips from the igniter pin. Remove the
graphite cover of the Cadweld Exolon mold.
Fig. 28
Fig. 29
Fig. 30
Cadweld Exolon graphite molds will last approximately 50
connections. Use a soft cotton cloth or a soft bristle brush (nVent
ERICO part #T394) to clean inside the mold cavity and cover;
remove any slag left from the exothermic reaction.
Fig. 31
The Cadweld One Shot Process
Fig. 1
Fig. 2
Gather the proper materials and equipment for the type of
connection you are making. The Cadweld One Shot system
requires a Cadweld One Shot ceramic mold, welding material, wire
brush for cleaning/preparing conductors, flint igniter, and propane
torch.
application. Refer to your mold instructions. Advise nearby personnel of
welding operations in the area prior to ignition.
Fig. 3
Check to ensure the ceramic mold is not broken, which could
cause leakage of molten weld metal during the reaction.
Inspect the Cadweld One Shot box label to ensure that it
corresponds to the application, indicated by the:
1. Cadweld One Shot part number
2. conductor size
Fig. 4
Cadweld One Shot connection.
Fig. 5
conductors and ground rod (Cadweld T-313 or
T-314 brush).
Fig. 6
Each Cadweld One Shot contains a rubber grommet
at the bottom of the mold.
Gently turn the Cadweld One Shot onto the ground
rod until the ground rod reaches the stopper and cannot go
any further.
Fig. 7
Fig. 8
Place the steel disk into the Cadweld One Shot
with the concave side facing up.
Fig. 9
Ensure that the steel disk is properly seated inside the
Cadweld One Shot.
Fig. 10
Next, take the tube of welding material included in the
Cadweld One Shot package and remove the lid
over the crucible.
Fig. 11
Quickly pour the loose welding material powder into the
Cadweld One Shot mold.
Fig. 12
Place the cover on the top of the Cadweld One Shot.
Fig. 13
The bottom of the tube contains compressed material
(starting material). Tap the bottom of the tube a couple of
times to loosen this material.
Fig. 14
Pour the starting material onto the Cadweld One Shot cover.
NOTE: Welding material is an exothermic mixture and reacts to produce
hot molten material with temperatures in excess of 2500 degrees
Fahrenheit (1400 degrees Celsius) and a localized release of smoke.
Avoid direct eye contact with “flash” of light from ignition of starting
material. Avoid inhalation of smoke/fumes.
Fig. 15
Aiming the flint igniter from the side, ignite the starting material
on the mold cover. Withdraw the igniter quickly to prevent fouling.
Fig. 16
Break the ceramic Cadweld One Shot mold off of the connection.
Avoid contact with hot materials. See the “Cadweld Quality
Standards” section to see whether a quality connection has been
made.
Fig. 17
You are ready to make another Cadweld One Shot connection.
The Cadweld Plus One Shot Process
Fig. 1
Fig. 2
connection you are making. The Cadweld Plus One Shot system
requires a Cadweld One Shot ceramic mold, Cadweld Plus
welding material, wire brush for cleaning/preparing conductors,
control unit, and propane torch.
application. Refer to your mold instructions.
Fig. 3
Check to ensure the ceramic mold is not worn or broken, which
Inspect the Cadweld Plus One Shot box label to ensure that it
corresponds to the application, indicated by the:
1. Cadweld Plus One Shot part number
2. conductor size
The mold must be correct for the conductor
size and application. DO NOT MODIFY MOLDS.
Fig. 4
Cadweld connection.
Fig. 5
Next, use a wire brush to further prepare the surface of
the conductors and ground rod (nVent ERICO T-313 or
T-314 brush).
Fig. 6
Each Cadweld Plus One Shot contains a copper wire at the
bottom of the mold.
Place the mold onto the ground rod until the ground rod reaches
the wire stopper and cannot go any further.
Fig. 7
Fig. 8
Inspect the cup to ensure it is tightly sealed and the ignition strip
is securely attached to the seal.
Fig. 9
Place the welding material cup into the top of the mold. Make sure
the ignition strip nests into the recess on the top edge.
Fig. 10
Place the ceramic lid onto the mold.
Fig. 11
Battery powered control unit.
Fig. 12
Place the ignition strip into the control unit connector. Remove or
protect fire hazards in close proximity to the connection. Advise
nearby personnel of welding operations in the area.
Fig. 13
Using the control unit, press the button and hold, while you
observe the “ready” indicator light. A green light will blink for a
few seconds and then will change to a constant light. At this
time, the unit will send a charge to the ignition strip. The ignition
strip will spark inside the metal cup, activating the Cadweld Plus
exothermic reaction.
Fig. 14
Remove and dispose of the used Cadweld Plus weld metal cup.
Fig. 15
Break the ceramic Cadweld One Shot mold off of the connection.
Avoid contact with hot materials. See the “Cadweld Quality
Standards” section to see whether a quality connection has been
made.
Fig. 16
You are ready to make another Cadweld connection.
Cadweld Quality Standards
All Cadweld materials are produced to high standards under
stringent quality control. All Cadweld connections are designed and
tested using Cadweld molds, welding materials, and accessories.
In the absence of any standards, national or international, we
cannot accurately predict the individual product standards of
our competition, either known or unknown. Therefore, mixing of
one manufacturer’s molds with another manufacturer’s welding
materials can predictably lead to finished welds that do not
meet the standards of either manufacturer. After all, one of the
advantages of exothermic welding as a welding process is the
fact that it is pre-engineered.
Specifications for Cadweld Connections
All grounding system connections shall be made by the Cadweld
process. Connections shall include, but not be limited to, all cable
to cable splices, T’s, X’s, etc.; all cable to ground rods, ground rod
splices, cable to steel and cast iron; and cable lug terminations.
Procedures listed in all Cadweld instructions shall be followed.
Molds shall not be altered in the field.
All materials used (molds, welding material, tools, accessories,
etc.) shall be Cadweld materials, manufactured by nVent ERICO.
Materials of different manufacturers shall not be mixed.
A Cadweld mold is designed to last for an average of 50
connections. This will vary according to the care given the mold
during use.
Inspect the mold regularly. Check the following items to
determine if a mold should be replaced:
CADWELD MOLD INSPECTION
Chip in mold
parting face
Disk seat worn

Mold parting
face smooth
Mold parting
Tap hole
face has
well defined
erosion lines
Chip in weld
cavity
Weld cavity
well defined Cable opening
worn
Good Replace
Cable Opening
• The conductor should fit snugly. A loose fit will cause leakage.
• The opening should not be chipped or worn.
Weld Cavity
• The cavity should be well defined.
• There should be no chips or gouges.
Tap Hole
• The tap hole should be well defined.
Disk Seat
• The seat should not be worn or chipped; the disk must seat
properly.
Mold Parting Face
• The parting face should not be chipped.
• The parting face should always be cleaned properly. Use a clean
shop towel or newspaper and wipe clean. Using a wire brush to
clean the mold will cause erosion and quickly destroy the mold.
INSPECTION OF CADWELD CONNECTIONS GENER AL

INDICATORS
Proper inspection of a Cadweld connection relies on the judgment

of the field personnel. Look closely at the size, color, surface
finish, and porosity of the connection.
Following the guidelines below will assist in making meaningful
inspections. Photographs of good, acceptable, and reject
connections appear on pages 14 – 17.
SIZE
1. No portion of the conductor within the confines of the weld

should be exposed.
2. Maximum depression under the riser on horizontal
connections (after the slag has been removed) should be no
lower than the top of the conductor.
A low fill indicates:
(a) Not enough welding material was used.
(b) Excessive leakage of molten metal.
(c) Improper positioning of the conductor inside the mold.
(d) Movement of conductor.
3. Excessively high fill (tall riser) indicates:

(a) Too large welding material size was used (connection is
still acceptable).
(b) Apparent volume increase due to contaminants in
conductor or mold (see “Porosity” on page 12).
Strands showing
(below weld level)
Unacceptable
Higher than normal
Normal
Minimum acceptable
Type VS
Higher than normal
Normal
Minimum acceptable
Type GT
Higher than normal

Normal
Minimum acceptable
Type SS
INSPECTION OF
CADWELD CONNECTIONS
GENER AL INDICATORS (CONTINUED)
Color
The color of a Cadweld connection is best seen after a light wire
brushing of the connection. It should normally be gold to bronze
in color. Occasionally, it may be silvery at the top. This silver color
indicates “tin sweat” of the surface, a normal condition.
A Cadweld connection to cast iron or galvanized surfaces is often
silvery due to alloying with the metals.
Surface Finish
The surface of a Cadweld connection should be reasonably
smooth and free of major slag deposits. If slag deposits cover
more than 20% of the connection surface, or if any cable strands
are exposed after slag has been removed, the connection must
be rejected.
Porosity
The connection should be essentially free from porosity.
Excessive porosity is normally the result of contaminants
(water, oil, dirt, etc.) in the conductor and/or mold. A few small
pinholes may be present on the surface of the riser. The depth of
a pinhole must never extend beyond the center of the conductor.
To check the depth, probe the pinhole with a 1/32-in.-diameter
wire (paper clip). Reject the connection if the depth of the pinhole
extends beyond the center of the conductor.
INSPECTION OF
CADWELD CONNECTIONS
VISUAL INSPECTION
Photographic Guides
Like all electrical connections, a visual inspection is no guarantee
of performance. Crimped or bolted connections cannot be
inspected visually, but Cadweld connections can be visually
inspected and provide an indication of the quality of the weld.
Visual inspection is recommended as a practical minimum.
Use the photographs on the following pages as a guide to visual
inspection. Cadweld connections are normally rated as good,
acceptable or reject.
A good connection is a normal weld with only minor surface
imperfections.
An acceptable connection is a less than normal weld, but a good
performing weld. Imperfections indicate that 1) a new mold is
required, 2) a change in procedure is necessary, or 3) the proper
mold conductor and/or welding material should be used.
A reject connection shows inadequate fill or an extra high
riser due to 1) use of incorrect procedure, 2) use of incorrect
equipment and/or equipment worn beyond its useful life, or 3)
use of incorrect material.
INSPECTION OF
CADWELD CONNECTIONS
PHOTOGR APHIC GUIDES
Good.
A solid weld with only minor surface imperfections.
Acceptable.
Fill is lower than normal, but still sufficient.
Reject.
A worn or incorrect mold was used, allowing leakage around
conductor. The fill in this connection is insufficient to allow it as
acceptable. Replacement of mold is required prior to making next
connection.
Acceptable.
The presence of water/moisture in conductor strands or mold
indicates that one or both were not properly dried. Although the
riser is porous, the weld is solid. The degree of porosity is not
sufficient to reject this connection.
Reject.
Extreme amounts of slag on surface are caused by welding
material leaking past disk or complete lack of disk. Inspect the
condition of mold disk seat and check disk positioning prior to
making the next connection.
Reject.
Excessive water in cable strands and/or mold.
INSPECTION OF
CADWELD CONNECTIONS
PHOTOGR APHIC GUIDES (CONTINUED)
Reject.
Light carbon traces on cable and connection are evidence of oil
on cable strands. Oily cables must be cleaned with safety solvent.
Reject.
Heavy carbon coating on cable and connection is evidence of large
amounts of oil or grease on cable. Cable must be cleaned with
safety solvent.
Reject.
Fill too low. Weld cavity was not filled over cable strands. “Fins”
indicate that the mold was not closed tightly due to incorrect
mold, incorrectly adjusted handle clamp, or presence of foreign
material in mold parting line. Before making the next connection,
check the mold for each of the above.
Reject.
Fill too low. Weld cavity was not filled over cable strands.
Absence of leakage indicates that welding material size was
incorrect (too small) or thru conductor moved.
FIELD SITUATION GUIDE
Most field difficulties can be overcome by checking the

following problems.
PROBLEM A
The mold doesn’t close tightly.

Check for:
1. Adjustment of handle clamps.

2. Cables out of round or bent.
3. Dirt or slag in mold parting line.
4. Correct cable size.
NOTE: Use “C” clamp if necessary.
PROBLEM B
The connection is covered with excessive slag.

Check for:
1. Welding material leaking past the disk, caused by:

(a) Chipped graphite at tap hole.
(b) Disk moved when welding material was dumped.
(c) Disk not properly seated.
(d) Disk was not installed.
NOTE: A small amount of slag on the surface is not abnormal.
PROBLEM C
Molten metal “spits” out of the crucible when making a

connection.
Remedy:
1. See Problem D.
PROBLEM D
The connection is porous

Check for:
1. Presence of moisture either in conductor or mold.

Remedy:
(a) Dry the conductor by wiping and heating.
(b) Heat mold with torch (to above 212°F) or by igniting
welding material in mold without any conductors, taking
care to prevent burns from the hot material running out
of the mold.
NOTE: Do not use the second method of heating if the mold
has wear plates.
Check for:
2. Other contaminants (oil, insulation, etc.) present in

conductors.
Remedy:
(a) Use a safety solvent to wash the conductor, then dry it.
(b) If insulation is present between strands, remove it.
Check for:
3. Mold packing material in weld cavity of mold.

Remedy:
(a)
Always apply mold packing material to conductor after
mold is closed.
PROBLEM E
The conductors do not weld

Check for:
1. Conductors were not properly cleaned and dried.

Remedy:
(a) Remove oxides with a wire brush. If heavily oxidized, have
fresh-cut conductor end and use Cadweld Heavy Duty
molds.
(b) Dry conductors with a torch.
Check for:
2. Conductors not properly positioned in the mold.

Remedy:
(a) Check for proper gap or butting as required (see the mold
tag and read the instructions packaged with mold).
Field Situation Guide (continued)
(b) Check to be sure gap is centered under tap hole.
NOTE: In some cases, the run (thru) conductor must be cut
and gapped. Follow instructions for same or use Cadweld
Heavy Duty molds.
PROBLEM F
The welding material leaks around the conductor.

Remedy:
1. Use packing material around the conductor after the mold is

closed.
2. Use molds with wear plates (which also act as chill plates).
3. Check for the proper mold. Mold must be sized for the cable
being welded.
4. If the mold is excessively worn, replace with a new mold.
PROBLEM G
The connection has “fins”— metal is lost.

Check for:
1. Mold not completely closed.

2. Mold worn beyond useful life and needs replacement.
PROBLEM H
The cables pull out of the mold during welding.
Remedy:
1. Use a clamp (Cadweld B-265) or other means to prevent

movement of conductors when welding.
PROBLEM I
Insufficient fill material to cover conductors

Check for:
1. Use of proper welding material size (see mold tag).

2. Too large a gap between conductors (see positioning
instructions).
3. Mold leakage.
Remedy:
(a) See Problem F.
(b) See Problem G.
(c) See Problem H.
4. Conductor movement.
PROBLEM J
The riser is too high.

Check for:
1. Use of proper welding material size (see mold tag).
2. Moisture in mold or conductor.
Remedy:
(a) See Problem D.
PROBLEM K
The mold wears out quickly.

(Molds should produce an average of 50 connections.)
Remedy:
1. Use Cadweld B-265 cable clamp for hard-drawn copper or

DSA Copperweld®.
2. Clean the mold with a soft brush, clean cloth, or newspaper.
DO NOT USE A WIRE BRUSH.
3. Use care in removing the mold from a finished connection to
prevent chipping of mold.
PROBLEM L
When welding to steel, the weld does not “stick” to the steel.
Remedy:
1. lean the steel with a rasp or grinder to bright metal.
C
When grinding, use an nVent ERICO approved grinding
wheel only. All mill scale, paint, and/or other coating must
be removed. Wire brushing will NOT suffice. Grease must be
removed with safety solvent before cleaning.
2. Clean galvanized surfaces with a wire brush or emery cloth.
However, extra heavy galvanized steel must be cleaned with
a rasp.
3. If the steel is moist, heat with a torch (from the back side
if possible). Any carbon deposit from the flame must be
removed.
4. If conductors are not in proper position, check the
instruction sheet.
Field Situation Guide (continued)
PROBLEM M
When welding to ductile iron or cast iron, the weld does not
“stick” to the surface.
Remedy:
1. Remove all coatings before cleaning.

2. Clean the surface with a rasp or grinder to bright metal. When
grinding, use an nVent ERICO-approved wheel only.
3. Clean the surface with a safety solvent after grinding or
rasping.
4. Use Cadweld XF-19 alloy welding material (orange cap).
Our powerful portfolio of brands:
CADDY ERICO HOFFMAN RAYCHEM SCHROFF TRACER
nVent.com/ERICO
©2018 nVent. All nVent marks and logos are owned or licensed by nVent Services
GmbH or its affiliates. All other trademarks are the property of their respective owners.
nVent reserves the right to change specifications without notice.
ERICO-CAT-E1294W-E297LT17WW-EN-1805

E1294W-WWEN NVent ERICO Cadweld Installation and Inspection Guide - Nvent

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

E1294W-WWEN NVent ERICO Cadweld Installation and Inspection Guide - Nvent

Uploaded by

Copyright:

Available Formats

The ERICO CADWELD Process

nVent ERICO Cadweld

The Cadweld Plus Process............................................11

The Cadweld Exolon Process.......................................19

The Cadweld One Shot Process.................................. 28

The Cadweld Plus One Shot Process......................... 33

Cadweld Quality Standards.......................................... 38

CADWELD MOLD INSPECTION

Disk seat worn

INSPECTION OF CADWELD CONNECTIONS GENER AL

Proper inspection of a Cadweld connection relies on the judgment

1. No portion of the conductor within the confines of the weld

3. Excessively high fill (tall riser) indicates:

Higher than normal

Higher than normal

Higher than normal

FIELD SITUATION GUIDE

Most field difficulties can be overcome by checking the

The mold doesn’t close tightly.

1. Adjustment of handle clamps.

The connection is covered with excessive slag.

1. Welding material leaking past the disk, caused by:

Molten metal “spits” out of the crucible when making a

The connection is porous

1. Presence of moisture either in conductor or mold.

2. Other contaminants (oil, insulation, etc.) present in

3. Mold packing material in weld cavity of mold.

The conductors do not weld

1. Conductors were not properly cleaned and dried.

2. Conductors not properly positioned in the mold.

The welding material leaks around the conductor.

1. Use packing material around the conductor after the mold is

The connection has “fins”— metal is lost.

1. Mold not completely closed.

1. Use a clamp (Cadweld B-265) or other means to prevent

Insufficient fill material to cover conductors

1. Use of proper welding material size (see mold tag).

The riser is too high.

The mold wears out quickly.

1. Use Cadweld B-265 cable clamp for hard-drawn copper or

1. Remove all coatings before cleaning.

CADDY ERICO HOFFMAN RAYCHEM SCHROFF TRACER

You might also like